Full Locked Coil Rope
Full locked cables, also known as full locked coil ropes, have a specialized and robust structure designed to maximize strength, durability, and resistance to external damage.
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Explore our extensive range of product forms, including customized wire ropes, slings, shackles, and hooks, all tailored to meet the specific needs of your projects. Our solutions are particularly suited for applications requiring high load-bearing capacity and corrosion resistance, ensuring optimal performance under tough conditions.
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Full locked coil ropes are a unique assembly of a classic wire rope core consisting of multiple helically twisted wires, with on top of that on the outside one or more layers of profiled, z-shaped wires that interlock with each other. This interlocking outer layer creates a dense rope assembly, with high strength & stiffness, and an aesthetically pleasing smooth outer surface. The cable voids on the inside are filled with our proprietary AULONE blocking compound, which reduces the impact of steel-steel contact, and adds a further barrier against corrosion.
Advantages
1)High breaking load and stiffness owing to its high metallic fill factor
2)Aesthetic and smooth outer surface add grace to your design
3)Factory assembly & pre-stress shorten your installation time
4)Can be extruded with plastic when colour aesthetics or additional corrosion resistance is needed
Wire coating: Zn or Zn95Al5
Coating of cable: conventional or HDPE Sheathing; Tensocoat
Reference standards: EN 12385-4
Dia/mm | Nominal Sectional Area(mm2) | Min Breaking Force（KN） |
φ40 | 1100 | 1580 |
φ45 | 1410 | 2000 |
φ50 | 1740 | 2470 |
φ55 | 2170 | 3020 |
φ60 | 2590 | 3590 |
φ65 | 2980 | 4220 |
φ70 | 3420 | 4890 |
φ75 | 3910 | 5620 |
φ80 | 4420 | 6390 |
φ85 | 4990 | 7210 |
φ90 | 5560 | 8090 |
φ95 | 6150 | 9110 |
φ100 | 6760 | 10100 |
φ105 | 7650 | 11100 |
φ110 | 8460 | 12200 |
φ115 | 9110 | 13400 |
φ120 | 9910 | 14500 |
φ125 | 10700 | 15800 |
φ130 | 11470 | 17300 |
φ135 | 12370 | 18630 |
φ140 | 13300 | 20000 |
Your Ultimate Guide to Acquiring Full Locked Coil Rope
Full locked coil ropes are specialized wire ropes known for their high strength, durability, and resistance to abrasion. They are predominantly used in demanding applications such as in cable cars, bridges, cranes, and other heavy lifting equipment. The construction of these ropes involves layers of wire strands that are locked together, providing excellent stability and longevity.
Table of contents
Chapt 1
What is Full Locked Coil Rope
Full locked cables are a type of wire rope designed to offer superior strength, durability, and resistance to abrasion and deformation. These cables are specifically engineered for heavy-duty applications that require high performance under significant loads and in demanding environments. They are often used in critical infrastructure projects such as bridges, cable cars, and cranes.
Understanding the Structure
Full locked coil ropes are composed of:
Core: Typically made from fiber or steel, providing the base support.
Inner Layers: Consist of round or shaped wires arranged in layers around the core.
Outer Layer: Made of interlocking wires, ensuring a smooth surface and high resistance to external damage.
1. Inner Core
Core Composition:
The inner core is composed of multiple layers of wires, typically made from high-strength steel.
These wires can be round or shaped and are arranged in a specific pattern to provide foundational strength and support.
Core Layers:
Central Strand: At the heart of the cable, there is often a central strand made of twisted wires. This central strand provides the initial framework and support.
Intermediate Layers: Surrounding the central strand are multiple layers of additional wires. These layers alternate in direction (right-hand and left-hand lay) to enhance the cable’s overall stability and strength.
2. Intermediate Layers
Round and Shaped Wires:
These layers consist of round and sometimes trapezoidal wires. The shaped wires help in filling the gaps between the round wires, which increases the density and strength of the cable.
Layer Arrangement:
The intermediate layers are carefully arranged to ensure even load distribution and minimize internal movement, which can cause wear and tear.
3. Outer Layer
Z-Shaped Wires:
The outermost layer is composed of Z-shaped wires. These wires are designed to interlock tightly with one another, forming a smooth and continuous surface.
The interlocking mechanism of these Z-shaped wires is a distinctive feature that sets full locked cables apart from other types of wire ropes.
Outer Protection:
This outer layer acts as a protective shield for the inner core, safeguarding it against abrasion, external impacts, and environmental factors such as moisture and chemicals.
The smooth surface reduces friction and wear, which is particularly beneficial in applications where the cable may rub against other surfaces or pulleys.
Visual Representation
A visual representation of the full locked cable structure would typically show:
Central Strand: A single, thick strand in the center.
Intermediate Layers: Several concentric layers of round and shaped wires surrounding the central strand.
Outer Layer: The final layer of tightly interlocking Z-shaped wires forming a smooth, protective outer surface.
In summary, the structure of full locked cables is meticulously designed to provide maximum strength, durability, and protection. This makes them ideal for critical applications in industries such as construction, mining, transportation, and offshore operations, where reliability and performance are paramount.
Chapt 2
Advantage of Fully Locked Coil Ropes
Fully locked coil ropes, also known as full locked coil ropes, offer several significant advantages due to their unique construction and robust design. These advantages make them highly suitable for demanding applications in various industries. Here are the key benefits:
1. High Tensile Strength
- Exceptional Load-Bearing Capacity: Fully locked coil ropes are designed to handle substantial loads. The multiple layers of high-strength steel wires, combined with the interlocking outer layer, provide exceptional tensile strength, making them suitable for heavy-duty applications.
2. Superior Durability
- Long Service Life: The robust construction of fully locked coil ropes ensures they can withstand harsh conditions and heavy use over extended periods. The tightly interlocked Z-shaped outer wires protect the inner core from damage, significantly enhancing the rope’s durability.
3. Excellent Abrasion Resistance
- Protection Against Wear: The smooth and continuous surface formed by the interlocking Z-shaped wires offers superior resistance to abrasion. This feature is particularly beneficial in environments where the rope may come into contact with abrasive surfaces or pulleys.
4. Minimal Stretch
- Stable and Precise Performance: Fully locked coil ropes exhibit very low elongation under load. This minimal stretch ensures stability and precise performance, which is critical in applications that require consistent and reliable operation.
5. Resistance to Crushing and Deformation
- Structural Integrity: The dense, interlocked structure of these ropes makes them highly resistant to crushing and deformation. This resistance helps maintain the rope’s structural integrity under heavy and constant loads.
6. Enhanced Protection from Environmental Factors
- Corrosion Resistance: The outer layer of interlocking wires provides a protective barrier that shields the inner core from environmental factors such as moisture, chemicals, and other corrosive elements. This protection helps prevent corrosion and extends the rope’s lifespan.
- Reduced Friction: The smooth outer surface reduces friction when the rope is in contact with other surfaces, decreasing wear and tear and enhancing overall performance.
7. Ease of Maintenance
- Inspection and Lubrication: While regular maintenance is essential, the design of fully locked coil ropes simplifies the process of inspection and lubrication. The outer layer’s smooth surface makes it easier to apply lubricants and identify any potential issues.
In summary, fully locked coil ropes offer numerous advantages that make them an ideal choice for critical and heavy-duty applications. Their high tensile strength, durability, abrasion resistance, minimal stretch, and protection from environmental factors ensure reliable and long-lasting performance in various demanding environments.
Chapt 3
Full Locked Coil Rope Production Procedure
To make a full locked coil rope, you need to go through a series of steps to ensure that the final product is up to par and meets the necessary quality and performance standards. This guide will walk you through the process from selecting the raw materials to inspecting the final product.
1. Raw Material Selection
Steel Wire
The main material for full locked coil rope is high-grade steel wire. The selection criteria include:
Tensile Strength: The steel must be able to withstand high tension and loads.
Corrosion Resistance: The steel should either have inherent corrosion resistance or be able to be further treated.
Ductility: The steel must be malleable enough to be drawn into fine wires without breaking.
Coating Materials
Depending on the application, the steel wires may be coated with materials such as zinc (galvanization) or plastic to enhance corrosion resistance and durability.
2. Wire Drawing
Initial Drawing
The steel rods are drawn through a series of dies to reduce their diameter. This process increases the strength and flexibility of the wires.
Intermediate Annealing
After the initial drawing, the wires undergo annealing, a heat treatment process that removes internal stresses and improves ductility. The wires are then drawn further to reach the desired diameter.
Final Drawing
The wires are drawn to their final diameters, ensuring precise dimensions and consistency. This step is crucial for the subsequent stranding process.
3. Stranding
Core Formation
The innermost part of the rope, the core, is formed by stranding a bundle of wires together. The core provides the central support for the entire rope.
Intermediate Layers
Several layers of wires are stranded around the core. Each layer is typically wound in an opposite direction to the previous layer to balance the rope and enhance its stability.
Outer Layer – Locked Coil
The outermost layer consists of Z-shaped wires that lock tightly together. These wires are precision-shaped to interlock, forming a smooth, compact surface that minimizes wear and friction.
4. Compaction
The stranded rope undergoes compaction to reduce its diameter and increase its density. This process improves the rope’s strength, wear resistance, and smoothness.
5. Lubrication and Coating
Lubrication
The rope is lubricated with special greases or oils to reduce friction between the wires and prevent internal corrosion. This step is essential for maintaining flexibility and extending the rope’s lifespan.
Coating
If you need more corrosion protection, you can coat the rope with zinc (galvanize) or plastic. Coating gives you an extra layer of protection from the environment.
6. Quality Control and Testing
Visual Inspection
We look at each rope to make sure it doesn’t have any visible defects like broken wires, strands that aren’t even, or surface problems.
Dimensional Checks
We measure the rope to make sure it’s the right diameter, length, and other dimensions.
Mechanical Testing
We test the rope to see how strong it is, how flexible it is, and how much weight it can hold before it breaks. We do these tests to make sure the rope can handle the loads and stresses you’re going to put on it.
Non-Destructive Testing (NDT)
We use NDT methods like magnetic particle inspection or ultrasonic testing to find out if there are any problems inside the rope without destroying it. This step makes sure the rope is safe and reliable.
7. Packaging and Storage
Packaging
We coil and secure the finished rope so it doesn’t get damaged when you ship it or store it. Good packaging keeps the rope safe.
Storage
We store the ropes in a controlled environment so they don’t get wet, too hot, or exposed to anything else that could hurt them.
Conclusion
Making full locked coil rope is a careful process. We choose good materials, use good manufacturing methods, and check the quality carefully. When we do all these things, we can make rope that works great, lasts a long time, and is safe.
If you have any questions or want to order rope, please get in touch with us at Aulone. We make great wire rope that you can customize. We also make sure it’s good with quality control and certification.
Chapt 4
Application Of Full Locked Cables
Full locked cables are highly specialized wire ropes designed for demanding applications where high strength, durability, and minimal stretch are required. Here are some key applications for full locked cables:
Bridges and Structures
- Suspension Bridges: Used as main cables to support the bridge deck, offering high tensile strength and durability.
- Stay Cables for Cable-Stayed Bridges: Provides stability and support for the bridge structure, ensuring long-term performance.
Offshore and Marine Applications
- Mooring Lines: Used for anchoring ships and offshore platforms, offering excellent resistance to harsh marine environments.
- Subsea Installation: Suitable for deep-sea operations, providing strength and reliability under extreme conditions.
Cable Cars and Ropeways
- Aerial Tramways: Provides reliable support and smooth operation for passenger and cargo transportation in mountainous or urban areas.
- Ski Lifts: Ensures safe and efficient transport of skiers and snowboarders on slopes.
Mining and Extraction
- Mining Hoists: Used in mining operations for lifting heavy loads and transporting materials to the surface.
- Drilling Rigs: Provides support for drilling equipment, ensuring safe and efficient operation.
By understanding these applications and benefits, you can better appreciate the value of full locked cables and make informed decisions when selecting the right wire rope for your specific needs.
Chapt 5
Full Locked Coil Rope Usage and Maintenance Guide
Proper usage and maintenance of full locked coil rope are essential to ensure safety, longevity, and optimal performance. Here’s a comprehensive guide to help you use and maintain full locked coil ropes effective
Usage Guidelines
Proper Installation
- Initial Inspection: Before installation, thoroughly inspect the rope for any visible damage, such as kinks, broken wires, or corrosion.
- Correct Handling: Handle the rope carefully to avoid kinking, bending, or other damage. Use appropriate tools and equipment for lifting and moving the rope.
- Tensioning: Properly tension the rope during installation. Ensure that the tension is even throughout the rope to avoid localized stress and potential damage.
Safe Operation
- Adhere to Load Limits: Never exceed the rated load capacity of the rope. Always operate within the manufacturer’s specified load limits.
- Avoid Shock Loads: Prevent sudden stops, impacts, or shock loads, which can cause internal damage to the rope.
- Proper Bending Radius: Ensure that the sheaves and drums used with the rope have the correct diameter to maintain the recommended bending radius. This helps to avoid excessive bending stress.
- Regular Monitoring: Continuously monitor the rope during operation for any signs of unusual wear, stretching, or damage.
Environmental Considerations
- Corrosion Protection: In corrosive environments, use ropes with appropriate coatings (e.g., galvanized, stainless steel) and apply protective lubricants regularly.
- Temperature Exposure: Be mindful of the operating temperature range. Extreme temperatures can affect the rope’s performance and lifespan.
Maintenance Guidelines
Routine Inspections
- Visual Inspection: Regularly inspect the rope visually for signs of wear, such as broken wires, corrosion, abrasion, and kinks. Pay special attention to high-stress areas like end fittings and sections that pass over sheaves and drums.
- Tactile Inspection: Run your hands along the rope (while wearing gloves) to feel for any deformities, broken wires, or other irregularities.
Lubrication
- Regular Application: Apply the recommended lubricant regularly to reduce friction, prevent corrosion, and enhance the rope’s lifespan. Follow the manufacturer’s guidelines for the type and frequency of lubrication.
- Proper Coverage: Ensure that the lubricant penetrates the rope’s core and covers all strands evenly. This helps in maintaining flexibility and preventing internal rust.
Tension Adjustment
- Periodic Re-Tensioning: Check and adjust the rope’s tension periodically to maintain optimal performance. Uneven tension can lead to premature wear and potential failure.
- Monitoring Tension: Use appropriate tools to measure the tension accurately and make necessary adjustments as needed.
Wear and Damage Replacement Criteria
- Broken Wires: Replace the rope if it has a significant number of broken wires, especially in critical areas. Follow industry standards and manufacturer guidelines for allowable broken wire limits.
- Corrosion: Replace the rope if there is significant corrosion that affects its structural integrity and load-bearing capacity.
- Deformation: Replace the rope if it exhibits any signs of deformation such as kinks, bird-caging, or crushing.
End-of-Life Replacement
- Service Life: Follow the manufacturer’s recommendations for the rope’s service life. Even if the rope appears to be in good condition, it should be replaced after reaching its recommended operational lifespan to ensure safety.
- Environmental Factors: Consider the operating environment and frequency of use when determining the rope’s service life. Harsh environments and high-frequency use may necessitate more frequent replacements.
Documentation and Records
Maintenance Logs
- Record Keeping: Maintain detailed records of all inspections, maintenance activities, and any issues observed. Include dates, findings, actions taken, and the personnel involved.
- Tracking Performance: Use these records to track the rope’s performance over time and identify patterns that may indicate potential issues.
Training and Education
- Personnel Training: Ensure that all personnel involved in the handling, installation, and maintenance of full locked coil ropes are properly trained and knowledgeable about the best practices and safety protocols.
- Continuous Education: Stay updated with the latest industry standards, manufacturer guidelines, and advancements in rope technology.
Conclusion
Proper usage and maintenance of full locked coil ropes are crucial for ensuring their safety, performance, and longevity. By following these guidelines, you can maximize the effectiveness of your ropes, reduce downtime, and enhance the overall efficiency of your operations.
Chapt 6
Quality Assurance For Full Locked Coil Rope
Ensuring the quality of full locked coil rope is crucial for safety, reliability, and performance. Quality assurance involves several steps from the manufacturing process to final installation and use. Here’s a detailed guide to implementing effective quality assurance for full locked coil ropes.
Manufacturing Quality Assurance
Raw Material Selection
- Material Quality: Use high-grade steel with appropriate tensile strength and chemical composition to ensure durability and performance.
- Supplier Certification: Source materials from reputable suppliers with proven quality standards and certifications such as ISO.
Manufacturing Process Control
- Precision Engineering: Ensure that the manufacturing process, including drawing, stranding, and closing, is performed with high precision to maintain consistency in rope construction.
- Equipment Calibration: Regularly calibrate and maintain manufacturing equipment to avoid deviations and defects.
Quality Control Tests
- Tensile Testing: Conduct tensile strength tests to verify that the rope meets or exceeds the specified load capacity.
- Dimensional Checks: Perform dimensional inspections to ensure the rope’s diameter, length, and construction are within specified tolerances.
- Non-Destructive Testing (NDT): Use NDT methods like magnetic flux leakage (MFL) to detect internal flaws or inconsistencies without damaging the rope.
- Fatigue Testing: Simulate cyclic loading conditions to assess the rope’s fatigue resistance and predict its lifespan.
Surface Treatment and Coating
- Galvanizing: Apply galvanizing to enhance corrosion resistance for ropes used in harsh environments.
- Lubrication: Ensure the rope is properly lubricated during manufacturing to reduce friction and prevent corrosion.
Certification and Compliance
Industry Standards
- ISO Certification: Ensure the rope complies with ISO standards relevant to wire ropes, such as ISO 2408.
- EN Standards: Adhere to European standards like EN 12385 for steel wire ropes.
Third-Party Certification
- Independent Testing: Engage third-party testing organizations to certify the rope’s quality and compliance with industry standards.
- Documentation: Obtain and review certification documents to verify compliance and quality.
Installation Quality Assurance
Pre-Installation Inspection
- Visual Inspection: Check for any visible defects, such as kinks, broken wires, or corrosion before installation.
- Dimensional Verification: Verify the rope’s diameter, length, and construction match the specifications.
Proper Handling
- Handling Procedures: Follow proper handling procedures to avoid damage during transport and installation.
- Use of Correct Tools: Utilize appropriate tools and equipment for lifting and installing the rope to prevent kinking or bending.
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